Instruction Manual 212 Pneudraulic Installation Tool

INSTRUCTION MANUAL 212 PNEUDRAULIC INSTALLATION TOOL

05-20-2004 Form HK838

212 Series Tooling Alcoa Fastening Systems

SAFETY

This instruction manual must be read with particular 5. When repairing or operating Huck installation attention to the following safety guide lines, by any equipment, always wear approved eye protec- person servicing or operating this tool. tion. Where applicable, refer to ANSI Z87.1 - 1989 1. Safety Glossary 6. Disconnect primary power source before doing Product complies with requirements maintenance on Huck equipment. set forth by the relevant European directives. 7. If any equipment shows signs of damage, wear, or leakage, do not connect it to the primary Read manual prior to using power supply. equipment. 8. Make sure proper power source is used at all Eye protection required while times. using this equipment. 9. Never remove any safety guards or pintail Hearing protection required while deflector. using this equipment. 10. Never install a fastener in free air. Personal injury from fastener ejecting may occur. ! WARNINGS - Must be understood to avoid severe personal injury. 11. When using an offset nose always clear spent pintail out of nose assembly before installing the CAUTIONS - show conditions that will dam- next fastener. age equipment and or structure. Notes - are reminders of required proce- 12. If there is a pinch point between trigger and dures. work piece use remote trigger. (Remote trig- Bold, Italic type and underlining - empha- gers are available for all tooling). sizes a specific instruction. 13. Do not abuse tool by dropping or using it as a 2. Huck equipment must be maintained in a safe hammer. Never use hydraulic or air lines as a working condition at all times and inspected on a handle. Reasonable care of installation tools by regular basis for damage or wear. Any repair operators is an important factor in maintaining should be done by a qualified repairman trained tool efficiency, eliminating downtime, and in pre- on Huck procedures. venting an accident which may cause severe personal injury. 3. Repairman and Operator must read manual prior to using equipment and understand any Warning 14. Never place hands between nose assembly and and Caution stickers/labels supplied with equip- work piece. ment before connecting equipment to any primary power supply. As applicable, each of the 15. Tools with ejector rods should never be cycled sections in this manual have specific safety and with out nose assembly installed. other information. 16. When two piece lock bolts are being used 4. See MSDS Specifications before servicing the always make sure the collar orientation is cor- tool. MSDS Specifications are available from rect. See fastener data sheet of correct posi- you Huck representative or on-line at tioning. www.huck.com. Click on Installation Systems Division.

3 212 Series Tooling Alcoa Fastening Systems

CONTENTS

Section Page Safety Guidelines ...... 3 Description ...... 5 Specifications ...... 5 Principle of Operation ...... 7 Preparation for Use ...... 8 Operating Instructions ...... 9 Maintenance ...... 10 & 11 Good Service Practices ...... 10 Preventive Maintenance ...... 11 Tool Maintenance ...... 11 Standard tools ...... 11 Nose Assembly Maintenance ...... 11 Filling and Bleeding Procedure ...... 12 & 14 How To Measure Stroke ...... 15 Troubleshooting ...... 16 Spare Parts and Service Kit ...... 16 Disassembly ...... 17 & 18 Assembly ...... 19 & 20 Parts List ...... 27 - 29 Notes and Specifications for Standard Parts ...... 30 Accessories ...... 30

4 212 Series Tooling Alcoa Fastening Systems

DESCRIPTION The Model 212 is a lightweight, high speed pro- system powered by 90-100 psi air pressure. The duction tool designed to install a wide range of air inlet is equipped with a connector with 1/4-18 Huck blind fasteners, and HUCKBOLT® female pipe threads to accept your air hose or Fasteners, including 3/16" and 1/4" diameter quick connect fitting. The piston return stroke is MAGNA-GRIP® Fasteners and MAGNA-LOK® spring actuated. Fasteners. A nose assembly is required for each fastener Pulling action of the pull piston is provided by a type and size. Nose assemblies must be pneumatic-hydraulic (pneudraulic) intensifier ordered separately.

SPECIFICATIONS

Weight 8.50 pounds (3.0 kg.) Length of Head (1) 9.00 inches (228 mm) Width of Head (1) 1.44 inches (37 mm) Edge to Centerline 72 inches (18 mm) Cylinder Diameter 4.63 inches (118 mm) Height13.00 inches (330 mm) Air Pressure 90-100 psi (620-690 kPa) Air Consumption* 6 CFM (0.003 m 3/s) Minimum Stroke .812 (20.6 mm) Minimum Pull Force @90 psi 5,200 psi (35,535 kPa)

* (based on 30 fastener installations per minute.)

(1) Weight and length of tool does not include nose assembly.

Fasteners installed: See SELECTION CHARTS or your Huck representative.

Hydraulic Fluid: Automatic Transmission fluid, *DEXRON II, III or equivalent.

DEXRON II & III are registered trademarks of General Motors Corporation.

5 212 Series Tooling Alcoa Fastening Systems

Fig. 1

Outline Drawing 6 212 Series Tooling Alcoa Fastening Systems

PRINCIPLE OF OPERATION When tool is connected to air supply, air pres- When fastener installation is completed, trigger sure holds throttle valve in up position - - air is released. Air pressure causes throttle valve to pressure is directed to top of piston keeping it return to its up position, reversing airflow. Air down. Depressing trigger moves throttle valve to piston and rod move down to their starting posi- down position - - air is directed to bottom of tion - - air is exhausted from below piston piston moving it upward. Air from above piston through muffler at bottom of tool. As rod moves is exhausted downward through throttle valve downward and hydraulic pressure is released and exits muffler at bottom of tool. Air piston rod from pull piston, a spring behind pull piston is a hydraulic piston - - pressurized fluid is returns it to its starting position. forced into head moving pull piston rearward.

Fig. 2

Sectional View 7 212 Series Tooling Alcoa Fastening Systems

PREPARATION FOR USE

! WARNINGS 1. Remove plastic plug from air inlet connector Do not pull on a pin without a collar. If and drop in a few drops of automatic trans- a pin is pulled without a collar, pin will mission fluid, DEXRON II, III or equivalent. eject forcibly when pintail separates. Severe personal injury may result. 2. Screw whip air hose and quick-connect fitting into air inlet connector. If deflectors are removed or damaged, separated pintails may eject forcibly 3. Set air pressure on regulator to 90 psi. from rear of tool. Severe personal injury may result. 4. Connect air hose to tool.

To avoid pinch points, be sure there is 5. Cycle tool a few times by depressing and adequate clearance for tool and opera- releasing trigger. tor’s hands before proceeding. Tool moving toward structure may cause severe 6. Disconnect air hose from tool. personal injury if clearance is limited. 7. Remove retaining nut.

Tool is shipped with a plastic plug in air inlet con- 8. Use pintail tube(s) as specified on NOSE nector. This connector has 1/4-18 female pipe ASSEMBLY DATA SHEET and/or FIGURE 2. threads to accept hose fining. Quick connect fittings and 1/4 inch inside diameter air hose are 9. Select nose assembly from SELECTION recommended. An air supply of 90 - 100 psi CHART for fastener to be installed, or see capable of 6 CFM must be available. The air Huck representative. Attach nose assembly supply should be equipped with a filter-regulator- to tool following applicable NOSE ASSEMBLY lubricator unit. DATA SHEET.

(1) Quick connect fittings and air hoses are not available from Huck.

8 212 Series Tooling Alcoa Fastening Systems

OPERATING INSTRUCTIONS PLEASE NOTE Blind Fastener Installation: Failure to understand WARNINGS may cause severe personal injury and failure to understand ! WARNING CAUTIONS may cause damage to structure and Do not pull on a pin without placing tool. fastener in a workpiece - - fastener will eject from front with velocity and force ! WARNINGS when pintail breaks off or teeth/grooves To avoid severe personal injury: Wear strip - - this may cause severe personal approved eye and ear protection. Be sure injury. of adequate clearance for operator’s hands before proceeding with fastener CAUTION installation. Be sure that pintail deflector Remove excess gap from between the sheets to is on tool and directed away from all per- permit correct fastener installation and prevent sonnel. jaw damage. ALL jaw teeth must engage pintail to avoid damaging teeth. HUCKBOLT® Fastener Installation: WARNING Fastener may be placed in workpiece or In end of ! Do not pull on a pin without placing nose assembly - - see WARNING. In either case, fastener/collar in a workpiece, and tool/nose must be held against work and at right also, collar chamfer MUST be out angles to it. Depress trigger - - hold trigger toward tool - - these conditions cause depressed until fastener is installed and pintail pin to eject with great velocity and breaks. Release trigger. Tool will go into its return force when the pintail breaks off or stroke. Tool/nose are ready for next installation teeth/grooves strip. This may cause cycle. severe personal injury. CAUTIONS BOM® blind fasteners jam in nose assembly if CAUTION pulled when not in workpiece. Remove excess gap from between the sheets. This permits enough pintail to To avoid structural and tool damage, be sure emerge from collar for ALL jaw teeth to enough clearance is allowed for nose assembly engage with pintail - - if ALL teeth do not at full stroke. engage properly, jaws will be damaged. Do not abuse tool by dropping it, using it as a Place pin in workpiece and place collar over pin - - hammer or otherwise causing unnecessary See WARNING. (If Collar has only one tapered wear and tear. end, that end MUST be out toward tool - - not next to sheet.) Hold pin and push nose assembly onto Reasonable care of tools by operators is an pin protruding through collar until nose anvil touches important factor in maintaining efficiency and collar. Depress trigger - - hold trigger depressed reducing downtime. until collar is swaged and pintail breaks. Release trigger. Tool will go into its return stroke. Tool/nose are ready for next installation cycle.

9 212 Series Tooling Alcoa Fastening Systems

MAINTENANCE Good Service Practices

The efficiency and life of any tool depends upon Rub SLIC-TITE TEFLON* thread compound, or proper maintenance and good service practices. equivalent, on pipe plug threads and quick con- Tool should be serviced by personnel who are nect fitting. CAUTION: Do not use Teflon tape thoroughly familiar with it and how it operates. on pipe threads. Pipe threads may cause tape to shred, resulting in tool malfunction. SLIC- A clean, well-lighted area should be available for TITE, 503237, is available in stick form from servicing the tool. Special care must be taken to Huck. Smear LUBRIPLATE 130AA*, or equiva- prevent contamination of pneumatic and lent, on seals (O-rings etc.) and mating surfaces hydraulic systems. Proper hand tools and soft to aid assembly and to prevent damage to seals. materials to protect tools must be available. Only LUBRIPLATE 13OAA, 502723, is available in a standard hand tools, brass drift and wood block tube from Huck. are required. Vise with soft jaws should be available. See Table 2 for tools available from Use VIBRA-TITE* on Gland (29) threads. Huck. VIBRA-TITE, 505125, is available from Huck. Follow directions on bottle. ALWAYS REPLACE ALL SEALS AND BACK- UP RINGS WHEN TOOL IS DISASSEMBLED Apply LOCTITE Adhesive/Sealant to Nut, FOR ANY REASON. 505420. LOCTITE, 503657, - - in a tube - - is available from Huck. Service Kit, 212KIT, All parts must be handled carefully and exam- includes perishable parts and should be kept on ined for damage and/or wear. Components hand. Other components, as experience dictates, should be disassembled and assembled in should also be readily available for replace- straight line without bonding, cocking or undue ments. force. DISASSEMBLY and ASSEMBLY proce- LUBRIPLATE is a trademark of Fiske Brothers Refining Co. dures outlined in this manual should be followed. TEFLON is a trademark oF E. I. DuPont de Nemours & Co.

VIBRA-TITE is a trademark of the Oakland Corporation.

LOCTITE is a trademark of Loctite Corp.

10 212 Series Tooling Alcoa Fastening Systems

MAINTENANCE (CONT.) Preventive Maintenance Nose Assembly Maintenance Tool Maintenance To extend jaw life: Disassemble nose assembly The 212 requires a minimum amount of mainte- periodically; clean and inspect components - - nance. Regular inspection and correction of use a pick to clean jaw grooves. CAUTION: minor problems will keep the tool operating effi- Wash pads in mineral spirits or isopropyl ciently and prevent downtime. alcohol ONLY. Dry O-rings; urethane jaw assemblies IMMEDIATELY after cleaning as pro- If a filter-regulator-lubricator unit is not being longed contact with solvent causes swelling - - used in the air supply: dry other parts. (1) Remove hose fitting from air inlet connector In nose assemblies without UNITIZEDTM jaws, and drop in a few drops of automatic trans- dip nose assembly in mineral spirits, isopropyl mission fluid or light oil. alcohol, or other suitable solvent, to clean jaws and wash away metal chips and dirt. If more (2) Blow out air line to remove dirt and water thorough cleaning or maintenance is necessary, before connecting air hose to tool. disassemble nose assembly. Use pick to remove particles packed in jaw grooves. Reassemble per At regular intervals, depending upon use, instructions on applicable NOSE ASSEMBLY replace all seals in tool. Service Kits should be DATA SHEET. kept on hand. (See SPARE PARTS AND SER- VICE KIT; NOTES.) Inspect both hydraulic pistons, and their piston rods for scored surfaces, excessive wear or damage, and replace as necessary.

CAUTION: Always replace seals and back-up rings when tool is disassembled for any reason.

STANDARD TOOLS AVAILABLE FROM HUCK

PART DESCRIPTION REF. P/N 502294 Hex Key, 1/8 across flats 45 504127 505898 Hex Key, 7116 across flats 35 116136 503904 Screw Driver 4 104293

11 212 Series Tooling Alcoa Fastening Systems

FILLING AND BLEEDING PROCEDURE

Equipment Required: Fig. 3

• Shop airline with 90- 100 psi max. • Air regulator • Fill bottle, 120337, (supplied with tool). • Large flat blade screwdriver • Nose assembly or optional stall nut • Fasteners • Optional stall nut, 124090

Stall nut is used to load tool during bleeding and for measuring stroke.

Preparation: 1. Install air regulator in airline and set pressure to 20-40 psi.

2. Fill bleed bottle almost full of DEXRON II or III - - ATF (automatic transmission fluid) - - see FIGURE 3.

Procedure to Fill Empty Tool (new or rebuilt) - - as Applicable: Fig. 3.1 1. Attach the tool air source momentarily to seat air piston at bottom of cylinder - - disconnect tool. With fillport facing up, lay tool on its side.

2. With a screwdriver, remove bleed plug from fillport.

! WARNING Air pressure MUST be set to 20 - 40 psi to prevent possible injurious high pressure spray. Never cycle tool without bleed plug tightened, fill bottle tightened in tool, or filIport held over 3. Screw fill bottle into fillport in the head. a receptacle (see FIGURE 3.1). When not properly contained any fluid pres- 4. Set airline pressure to 20 - 40 psi and ent in tool will spray out. Severe connect airline to tool. injury may result.

12 212 Series Tooling Alcoa Fastening Systems

FILLING AND BLEEDING PROCEDURE (CONT.)

5. Stand tool upright on bench. While triggering Bleed Procedure for Partially Filled Tool in tool slowly (20 - 30 cycles), bend fill bottle at Field Use - - as Applicable: right angles to tool- - see FIGURE 3.2. Air bubbles will emerge from tool. When bubbles 1. Disconnect tool from airline. With fillport stop, cycling may be discontinued. facing up, lay tool on its side.

Fig. 3.2 2. Remove bleed plug from bleed port. 3. Hold tool over suitable container with fillport facing into container.

! WARNING Air pressure MUST be set to 20- 40 psi to prevent possible injurious high pressure spray. Never cycle tool without bleed plug tightened, fill bottle tightened in the tool, or the fillport held over a receptacle (see FIGURE 3.3). When not properly contained any fluid present in tool will spray out. Severe injury may 6. When trigger is released, pull piston returns result. to idle position (full forward). Disconnect tool from airline. Fig. 3.3

7. Lay tool on its side. Remove fill bottle. Top off fluid in fillport. Install bleed plug and tighten.

8. Connect airline to tool. There is a choice of two procedures for measuring the stroke - - with and without a stall-nut - - see appropriate section and follow the selected procedure. If stroke is less than specified, remove bleed plug and top off fluid. Reinstall bleed plug.

9. Increase air pressure to specification. Install 4. Connect tool to airline. cycle tool several times two fasteners to check function and installation to drain the old fluid, air and foam. in a single stroke, or cycle tool with stall-nut fully threaded onto piston to load up tool. 5. Screw fill bottle into fillport. Measure stroke again. Remove plug and top off fluid. Reinstall plug and cycle again - - 6. See warning above. With air pressure set at 20 measure again. Continue this process until - 40 psi, connect airline to tool stroke meets minimum requirements,

13 212 Series Tooling Alcoa Fastening Systems

FILLING AND BLEEDING PROCEDURE (CONT.)

7. Stand tool upright on bench. While Fig. 3.4 actuating the trigger slowly (20 - 30 cycles), bend fill bottle at right angles to tool - - see FIGURE 3.4. Observe that air bubbles emerge from tool. When bubbles are no longer observed, cycling may be discontinued.

8. When trigger is released, pull piston returns to idle position (full forward). Disconnect tool from airline with piston full forward.

9. Lay tool on its side. Remove fill bottle. Top off fluid in fillport. Install bleed plug and tighten with screwdriver.

10.Connect airline to tool. There is a choice of two procedures for measuring the stroke - - with and without a stall-nut - - see appropriate section and follow the selected procedure. If stroke is less than specified, remove bleed plug and top off fluid. Reinstall bleed plug.

11. Install two fasteners to check function and installation in a single stroke, or cycle tool with stall nut fully threaded onto piston. Measure stroke again. Remove plug and top off fluid. Reinstall plug and cycle again - - measure again. Continue this process until stroke meets minimum requirements.

14 212 Series Tooling Alcoa Fastening Systems

HOW TO MEASURE STROKE To measure stroke of tool with stall- To measure stroke of tool without nut threaded onto piston: stall-nut: 1. Disconnect tool from airline -- remove nose from tool. 1. Disconnect tool from airline - - remove nose from tool. 2 With piston fully forward (end of RETURN stroke), bottom the stall-nut on piston. Back 2. With piston fully forward (end of RETURN stall-nut off five (5) turns. stroke), measure and record “X” dimension - - see FIGURE 4.1. 3. Cycle tool and hold trigger depressed - - this keeps piston fully to the rear and at end 3. Hold trigger depressed. Piston is now fully to of PULL stroke. Thread stall-nut back onto the rear and at end of PULL stroke. Measure piston until it contacts stop. and record “Y” dimension. 4. Release trigger. Stall-nut wilI move forward with piston. See FIGURE 4 and measure “X” 4. Subtract “X” dimension from “Y” dimension. dimension. This is the tools stroke. 5. If stroke is less than .812, refer to appropriate 5. If stroke is less than .812, refer to appropri- previous section. Follow filling and topping off ate previous section. Follow filling and top- instructions. ping off instructions

Fig. 4 Fig. 4.1

15 212 Series Tooling Alcoa Fastening Systems

TROUBLESHOOTING Always check out the simplest possible cause of located. Where possible, substitute known good a malfunction first. For example, an air hose not parts for suspected bad parts. Use this page as connected. Then proceed logically, eliminating an aid in locating and correcting malfunction: each possible cause until the defective part is 1. Tool fails to operate when trigger is depressed. a. Throttle valve O-ring (53) or O-ring (54) worn or damaged. b. Broken throttle cable.

2. Tool does not complete fastener installation or break pintail. a. Air pressure too low. Set to 90 psi. b. Hydraulic fluid low causing short stroke. c. Air piston QUAD Ring (40) worn or damaged. d. Air in hydraulic system (see FILLING AND BLEEDING TOOL).

3. Hydraulic fluid exhausts with air. a. Worn or damaged O-ring (37) and Back-up Ring (36) or O-ring (30); O-ring (33) and Back-up Ring (34); POLY-SEAL (32) or QUAD Ring (31).

4. Hydraulic fluid leaks at Hydraulic Cylinder Head (14). a. Worn or damaged Pull Piston Rod POLY-SEAL (7).

5. Hydraulic fluid leaks at Pull Piston Rod (6). a. Worn or damaged Pull Piston Rod POLY-SEAL (7).

6. Pull Piston (6) will not return. a. Broken or weak Spring (13).

7. Air leaks at air Cylinder Head (43). a. O-ring (44) damaged.

SPARE PARTS AND SERVICE KIT

The quantity of spare parts that should be kept etc., should be kept on hand. Parts included in on hand varies with application and number of SERVICE KIT 212KIT, are indicated by asterisks tools in service. Service parts kit containing per- (*) in PARTS LIST. ishable parts such as O-rings, back-up rings,

16 212 Series Tooling Alcoa Fastening Systems

DISASSEMBLY See applicable illustrations. 4. Pull Deflector (17) off End Cap (14).

For parts identification, refer to applicable fig- 5. Using wrench, unscrew End Cap (14). Slide ures, tables and parts lists. Numbers in paren- out Spring (13) theses ( ) are reference numbers shown in manual. 6. CAUTION - - to prevent damage to Piston WARNING Seals and Gland Seals when removing ! Be sure air hose is disconnected before them - - install OPTIONAL POLY-SEAL cleaning or when replacing worn or Insertion Tool (121694-212). damaged tool components. Tool may be actuated if not disconnected and Thread POLY-SEAL Insertion Tool, 121694- cylinder is under pressure. Severe 212, into head/handle. personal injury may result. 7. Slide Spacer, 123112-2, over piston rod.

The following procedure is for complete disas- 8. Thread Piston Assembly Tool, 123111-2, onto sembly of tool. Disassemble ONLY those compo- piston. nents necessary to replace damaged or worn O- rings, QUAD rings, back-up rings and other com- 9. Push complete piston from front using brass ponents. drift - -allow clearance for piston as it exits tool. 1. Disconnect tool from air source. 10.Remove Piston Assembly Tool, Spacer, and 2. Unscrew Retaining Nut (2) and remove Nose POLY-SEAL Insertion Tool. Assembly. Remove Pintail Tube (1). 11.Inspect Piston (6) for wear, scoring or dam- 3. Unscrew Bleed Plug (4) including O-ring (5) age. Replace when necessary. Remove from top of Handle/Head (3). Turn tool over Retaining Ring (64) and Washer (63). Hold and allow fluid to drain into container - - tool tool securely with bottom up. may be cycled to clear tool more completely. Discard fluid. 12.Remove three Button Head Screws (51) with 1/8 hex key. Remove Muffler End Cap (50) WARNING ! and Bottom Exhaust Gasket (48). Remove Never cycle tool without bleed plug Muffler (47) with O-ring (46) from end cap. installed and tightened, the bottle installed and tightened in tool head, or 13.Remove Retaining Ring (45) from Cylinder the fillport held over a suitable con- (24). tainer. If fluid is present it will spray out of tool. Severe eye injury may 14. Screw Button Head Screws (51) back into result. Air pressure MUST be set at 20 - 40 psi. Cylinder Head (43). Carefully pull on screws to remove Cylinder Head (43).

17 212 Series Tooling Alcoa Fastening Systems

DISASSEMBLY (CONT.) 15.Screw 1/4-20 UNC screws into Piston (39). 18.Remove Throttle Arm (22). Detach ball end of Pull evenly on screws to remove assembled Cable Assembly (21) from throttle arm. Drive Piston and Rod - - as an alternative, pull on Slotted Pin (18) from Handle (3) and remove Lock Nut (42) with VISE-GRIP pliers. Trigger (20) with attached Cable Assembly (21) and Linkage Pin (19). Push out linkage CAUTION pin and remove cable assembly from trigger. Do not scratch, nick, or ding Piston Rod (41). This will cause permanent hydraulic leakage. 19.Pull Throttle Valve (52) out of Cylinder (24).

16.CAUTION: DO NOT remove Gland (29) before 20.NOTE: Do not remove bushings unless air throttle arm pivot Shoulder Screw (23) is leakage cannot be stopped by replacing all removed. These parts will be damaged if this three throttle valve 0-rings. removal sequence is not followed. If bushing replacement is necessary, press out Remove bumper (38) from Gland (29). Lower Bushing (59) and Upper Bushing (58). Unscrew Gland (29) with 1 3/8 socket Use square ended brass rods at least six wrench. inches long. With proper size rod, press out lower bushing first, press out upper bushing 17.Lift Cylinder (24) from Handle/head (3). Turn using a larger diameter rod. handle/head over, and drain hydraulic fluid into container. Discard fluid.

Note: Do not attempt to remove Oil Damper Valve (56 & 57) - - no service is required on these parts

18 212 Series Tooling Alcoa Fastening Systems

ASSEMBLY See applicable illustrations. 6. CAUTION: DO NOT install Throttle Arm Pivot Shoulder Screw (23) before Gland Clean all components with mineral spirits, and (29) is installed to avoid damage to these inspect for wear or damage. Replace as neces- parts. sary. Always replace all seals and back-up rings on/in disassembled components. Use Apply VIBRATITE (Huck 505125) to threads O-rings, QUAD rings and back-up rings supplied of Gland Assembly (29) - - follow directions on in Service Kit, 212KlT - - see NOTES. Smear container. Screw gland into head/handle. LUBRIPLATE 13OAA or PARKER-O-LUBE on Using 1 3/8 socket wrench, tighten gland to seals. 90 ft. lbs. + 10 lbs.

1. If bushings are being replaced: 7. Push Bumper (38) firmly over Gland (29) - - face of bumper with two slots must face Note: Use LOCTITE 609, (Huck 503377) on toward bottom of tool. bushings when pressing into cylinder. 8. Carefully press assembled Piston (39). Rod Use an arbor press. Place chamfered end of (41). Nut (42), and QUAD Ring (40) into Upper Bushing (58) in top of Cylinder (24). Cylinder/handle (3) through Gland Assembly, Carefully press bushing squarely into cylinder. 116134. Repeat procedure for Lower Bushing (59). 9. Push Cylinder Head (39) squarely into 2. After new bushings are installed they may head/handle taking care not to damage O-ring have to be reamed, lapped, and honed to (44). Install Retaining Ring (45). bring their inside diameters to size for correct fit and alignment with throttle valve. 10. Position O-ring (46) and Muffler (47) on center of Cylinder Head (43). Position Gasket (48) 3. Position Cable Assembly (21) in Trigger (20) on cylinder and Spring (28) in lower bushing. slot and push Linkage Pin (19) through holes in trigger and cable assembly. Position 11. Carefully position Muffler End Cap (50) on assembled trigger in Handle (3) and push cylinder - - be certain that muffler is properly Slotted Pin (18) through holes in handle and positioned in recess of muffler end cap. trigger. 12. Hold end cap down and screw in three 4. Hold Head/handle (3) securely with lower end Button Head Screws (51) and tighten with 1/8 pointing up. Turn Cylinder (24) bottom up, and hex key. line up cylinder pin with handle hole. Press Handle onto cylinder. 13. Place tool upright on level surface. Push 5. Assemble Gland Assembly - - see FIGURE Throttle Valve (52) into cylinder. 12 14. Place ball end of Throttle Cable (21) in end of Note: Cup of POLY-SEAL (32) must face Throttle Arm (22). toward top of tool when installed in Gland (29). 15. Slide throttle arm into slot on Throttle Valve (52). Use new replacement POLY-SEAL (32), Spacer and SPIRO-LOX Retaining Ring (34).

19 212 Series Tooling Alcoa Fastening Systems

ASSEMBLY (CONT.) 16. Install Shoulder Screw (23) in head/handle (3) 20.Push gland assembly onto piston rod. to retain throttle arm. 21.Push wiper onto piston rod. 17. Install POLY-SEAL (7), Washer (63) and Retaining Ring (64) into Piston (6). 22.Push assembled components in gently from rear of tool using a press or a soft mallet and drift. 18. Caution: To prevent damage to piston POLY-SEAL 23.Remove Piston Assembly Tool and POLY- and gland POLY-SEAL, use OPTIONAL SEAL Insertion Tool Slide Spring (13) over pis- POLY-SEAL Insertion Tool . ton extension. Screw End Cap (50) into cylinder and tighten. Thread POLY-SEAL Insertion Tool, 121694- 212, into head/handle. 24. Push Deflector (17) onto end cap.

19.Thread Piston Assembly Tool, 123111-2, onto partially assembled piston.

20 212 Series Tooling Alcoa Fastening Systems

Fig. 5

Handle Assembly 21 212 Series Tooling Alcoa Fastening Systems

Fig. 6

Caution: Assemble seals as shown

Piston Assembly

Fig. 9

Caution: Assemble seals as shown

Front Gland Assembly 22 212 Series Tooling Alcoa Fastening Systems

Fig. 10

Piston and Gland Removal 23 212 Series Tooling Alcoa Fastening Systems

Fig. 11

Piston and Gland Insertion/assembly 24 212 Series Tooling Alcoa Fastening Systems

Fig. 12

Gland Assembly 25 212 Series Tooling Alcoa Fastening Systems

Fig. 13

Cylinder Assembly 26 212 Series Tooling Alcoa Fastening Systems

PARTS LIST

Ref. P/N Qty. Description 1 100534-1 1 Pintail Tube 2 111795 1 Retaining Nut 3 119653 1 Handle/head (see footnote 1) 4 104293 1 Bleed Plug Assem. (incl. ref. 5; see footnote 1) 5* 505438 1 O-ring 6 120827 1 Piston Assembly (incl. ref. 7, 63, 64) 7* 505865 1 POLY-SEAL 8 122430 1 Front Gland Assembly (incI. 9,10,61) 9* 503806 1 O-ring 10* 505827 1 POLY-SEAL 11* 505817 1 Wiper 12 Not Used ------13 505946 1 Spring 14 119658 1 End Cap 15 Not Used ------16 Not Used ------17* 118809 1 Deflector 18 500619 1 Slotted Pin - - .125 x 5/8 long 19 116407 1 Linkage Pin 20 116262 1 Trigger 21 116404 1 Cable Assembly 22 116405 1 Throttle Arm 23 116916 1 Shoulder Screw 24 115555 1 Cylinder Assembly (incI. 25, 58, 59) - - 501352 1 Dowel Pin (not shown)

27 212 Series Tooling Alcoa Fastening Systems

PARTS LIST (CONT.)

Ref. P/N Qty Description 26 Not Used ------27 Not Used ------28 116272 1 Return Spring - - 116134 1 Gland Assembly (incI. 29 through 37) 29 123905 1 Gland Housing 30* 500786 1 O-ring 31* 501414 1 QUAD Ring 32* 506566 1 POLY-SEAL 33* 123906 1 Spacer 34* 506565 1 Retaining Ring 35 Not Used ------36* 501090 1 Back-up Ring 37* 500784 1 O-ring 38 116408 1 Bumper 39 116636 1 Piston Assembly (incI. 40) 40* 501460 1 QUAD Ring 41 111803 1 Piston Rod 42 121241 1 Nut 43 112434 1 Cylinder Head Assembly (incI. 44) 44* 500873 1 O-ring 45 505025 1 Retaining Ring - - Spirolox PR 412 46* 500777 1 O-ring 47 115554 1 Muffler 48 118291 1 Bottom Exhaust Gasket 49 Not Used ------

28 212 Series Tooling Alcoa Fastening Systems

PARTS LIST (CONT.)

No. P/N Qty Description 50 116585 1 Muffler End Cap 51 504127 3 Screw-Button Hd.- -10-32 x 5/8 long 52 115558 1 Throttle Valve Assem. (incI. 28, 53, 54) 53* 504407 1 O-ring 54* 504408 2 O-ring 55 120588 1 Anvil Stop 56 123149 1 Damper 57 Not Used ------58 115504 1 Bushing Upper 59 115503 1 Bushing Lower 60 115436 1 Air Hose 61 121377 1 Damper Tube 62 122432 1 Gland Cap 63* 506654 1 Washer 64* 506653 1 Retaining Ring

(1) For replacement of machined handle/head only, Handle/head, 119653 and Bleed Plug Assembly, 104293 are required.

(2) When Bleed Plug Assem. 104293, has been removed and reinstalled in tool 5 times, NYLOK locking element in plug becomes worn out, therefore, worn out bleed plug must be replaced with new plug to prevent hydraulic fluid loss.

Rev 6-20-94 includes: (29)(32)(33)(34)(35)

Rev 9-1 -94 includes: (6)(7)(42)(43)(56)(63)(64)

29 212 Series Tooling Alcoa Fastening Systems

NOTES AND SPECIFICATIONS FOR STANDARD PARTS

1. All part numbers shown in this manual are available from Huck. The 500000 series part numbers are standard parts which generally can be purchased locally.

2. Asterisks (*) indicate parts in Service Kit, 212KIT.

3. O-ring sizes are specified AS 568 dash numbers. (AS 568- is an AEROSPACE SIZE STANDARD FOR O-RINGS and formerly was known as ARP 568-).

4. QUAD ring sizes are specified Q4 plus 3 digits. The last 3 digits correspond to O-ring dash numbers. QUAD rings are manufactured by Minnesota Rubber Co. unless otherwise specified.

5. Back-up rings are W. S. Shamban & Co. series S-11248, single turn TEFLON (MS-28774), or equivalent. The dash numbers correspond to the O-ring AS 568 dash numbers.

6. Material for O-rings and QUAD rings:

a. Ref. nos. 15, 30, 31, 40, 37, 44 and 46 are Nitrile or Buna N (Minnesota Rubber Co., compound 386Y, or equivalent), 70 durometer.

b. Ref. nos. 53 and 54 are VITON, (Parker Seal Co., compound V747-75, or equivalent) 75 durometer.

c. Ref. nos. 5 and 9 are Disogrin Industries. Compound 9250, or equivalent., 90 durometer.

ACCESSORIES

120809 Assembly Tool Kit includes: Fill and Bleed Bottle: 120337 123111-2 Piston Assembly Tool 123112-2 Spacer 100534-1 Pintail Tube: to be used with 121694-212 POLY-SEAL Insertion Tool -04(1/8) and -05(5/32) diameter fasteners. Full articulated air swivel: 114748

30 212 Series Tooling Alcoa Fastening Systems

LIMITED WARRANTIES Tooling Warranty: Huck warrants that tooling and other CHANTABILITY OR FITNESS FOR USE OF ANY TOOL, items (excluding fasteners, and hereinafter referred as PART(S), OR OTHER ITEMS THEREOF NOT MANU- "other items") manufactured by Huck shall be free from FACTURED BY HUCK. HUCK SHALL NOT BE LIABLE defects in workmanship and materials for a period of nine- FOR ANY LOSS OR DAMAGE, DIRECTLY OR INDI- ty (90) days from the date of original purchase. RECTLY, ARISING FROM THE USE OF SUCH TOOL- ING, PART(S) OR OTHER ITEMS OR BREACH OF Warranty on "non standard or custom manufactured WARRANTY OR FOR ANY CLAIM FOR INCIDENTAL products": With regard to non-standard products or cus- OR CONSEQUENTIAL DAMAGES. tom manufactured products to customer's specifications, Huck warrants for a period of ninety (90) days from the The only warranties made with respect to such tool, part(s) date of purchase that such products shall meet Buyer's or other items thereof are those made by the manufactur- specifications, be free of defects in workmanship and er thereof and Huck agrees to cooperate with Buyer in materials. Such warranty shall not be effective with enforcing such warranties when such action is necessary. respect to non-standard or custom products manufactured using buyer-supplied molds, material, tooling and fixtures Huck shall not be liable for any loss or damage resulting that are not in good condition or repair and suitable for from delays or nonfulfillment of orders owing to strikes, their intended purpose. fires, accidents, transportation companies or for any reason or reasons beyond the control of the Huck or its sup- THERE ARE NO WARRANTIES WHICH EXTEND pliers. BEYOND THE DESCRIPTION ON THE FACE HEREOF. HUCK MAKES NO OTHER WARRANTIES AND Huck Installation Equipment EXPRESSLY DISCLAIMS ANY OTHER WARRANTIES, Huck International, Inc. reserves the right to make INCLUDING IMPLIED WARRANTIES AS TO MER- changes in specifications and design and to discontinue CHANTABILITY OR AS TO THE FITNESS OF THE models without notice. TOOLING, OTHER ITEMS, NONSTANDARD OR CUS- TOM MANUFACTURED PRODUCTS FOR ANY PARTIC- Huck Installation Equipment should be serviced by trained ULAR PURPOSE AND HUCK SHALL NOT BE LIABLE service technicians only. FOR ANY LOSS OR DAMAGE, DIRECTLY OR INDI- Always give the Serial Number of the equipment when cor- RECTLY, ARISING FROM THE USE OF SUCH TOOL- responding or ordering service parts. ING, OTHER ITEMS, NONSTANDARD OR CUSTOM MANUFACTURED PRODUCTS OR BREACH OF WAR- Complete repair facilities are maintained by Huck RANTY OR FOR ANY CLAIM FOR INCIDENTAL OR International, Inc. Please contact one of the offices listed CONSEQUENTIAL DAMAGES. below. Huck's sole liability and Buyer's exclusive remedy for any Eastern breach of warranty shall be limited, at Huck's option, to One Corporate Drive Kingston, New York 12401-0250 replacement or repair, at FOB Huck's plant, of Huck man- Telephone (845) 331-7300 FAX (845) 334-7333 ufactured tooling, other items, nonstandard or custom products found to be defective in specifications, workman- Canada ship and materials not otherwise the direct or indirect 6150 Kennedy Road Unit 10, Mississauga, Ontario, cause of Buyer supplied molds, material, tooling or fix- L5T2J4, Canada. tures. Buyer shall give Huck written notice of claims for Telephone (905) 564-4825 FAX (905) 564-1963 defects within the ninety (90) day warranty period for tool- Outside USA and Canada ing, other items, nonstandard or custom products Contact your nearest Huck International Office, see back described above and Huck shall inspect products for which cover. such claim is made. In addition to the above repair facilities, there are Tooling, Part(s) and Other Items not manufactured by Authorized Tool Service Centers (ATSC's) located Huck. throughout the United States. These service centers offer HUCK MAKES NO WARRANTY WITH RESPECT TO repair services, spare parts, Service Parts Kits, Service THE TOOLING, PART(S) OR OTHER ITEMS MANUFAC- Tools Kits and Nose Assemblies. Please contact your TURED BY THIRD PARTIES. HUCK EXPRESSLY DIS- Huck Representative or the nearest Huck office listed on CLAIMS ANY WARRANTY EXPRESSED OR IMPLIED, the back cover for the ATSC in your area. AS TO THE CONDITION, DESIGN, OPERATION, MER- For the Long Haul™

A Global Organization Alcoa Fastening Systems (AFS) maintains company industrial and Aerspace centers, where they provide offices throughout the United States and Canada, a ready source of AFS fasteners, installation tools, with subsidiary offices in many other countries. tool parts, and application assistance. Authorized AFS distributors are also located in many of the world’s

Alcoa Fastening Systems world-wide locations:

Americas Far East Europe

Alcoa Fastening Systems Alcoa Fastening Systems Alcoa Fastening Systems Alcoa Fastening Systems Aerospace Products Commercial Products Commercial Products Commercial Products Tucson Operations Kingston Operations Australia Operations United Kingdom Operations 3724 East Columbia 1 Corporate Drive 14 Viewtech Place Unit C, Stafford Park 7 Tucson, AZ 85714 Kingston, NY 12401 Rowville,Victoria Telford, Shropshire 800-234-4825 800-431-3091 Australia 3178 England TF3 3BQ 520-747-9898 845-331-7300 03-764-5500 01952-290011 FAX: 520-748-2142 FAX: 845-334-7333 Toll Free: 008-335-030 FAX: 0952-290459 www.hucktools.com FAX: 03-764-5510 Alcoa Fastening Systems Alcoa Fastening Systems Alcoa Fastening Systems Aerospace Products Aerospace Products Commercial Products France Operations Carson Operations Canada Operations Clos D’Asseville PO Box 5268 6150 Kennedy Road, Unit 10 BP4 900 Watson Center Rd. Mississagua, Ontario L5T2J4 95450 Us Par Vigny Carson, CA 90749 Canada France 800-421-1459 905-564-4825 33-1-30-27-9500 310-830-8200 FAX: 905-564-1963 FAX: 33-1-34-66-0600 FAX: 310-830-1436

Alcoa Fastening Systems Alcoa Fastening Systems Commercial Products Commercial Products Waco Operations Latin America Operations PO Box 8117 Avenida Parque Lira. 79-402 8001 Imperial Drive Tacubaya Mexico, D.F. Waco,TX 76714-8117 C.P.11850 800-388-4825 FAX: 525-515-1776 254-776-2000 TELEX: 1173530 LUKSME FAX: 254-751-5259

For The Long Haul,The Future of Fastening Technology, and/or the means for selecting such products, and is not intended The Future of Assembly Technology,The Future of Tooling to create any warranty, express, implied, or statutory; all warranties Technology, and Tools of Productivity are service marks of Huck are contained only in Huck’s written quotations, acknowledge- International. Huck provides technical assistance regarding the use ments, and/or purchase orders. It is recommended that the user and application of Huck fasteners and tooling. secure specific, up-to-date data and information regarding each application and/or use of such products. NOTICE:The information contained in this publication is only for SM general guidance with regard to properties of the products shown HWB898 1003-5M One Great Connection